US20030007790A1 - Water heater - Google Patents
Water heater Download PDFInfo
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- US20030007790A1 US20030007790A1 US09/897,036 US89703601A US2003007790A1 US 20030007790 A1 US20030007790 A1 US 20030007790A1 US 89703601 A US89703601 A US 89703601A US 2003007790 A1 US2003007790 A1 US 2003007790A1
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- water
- water heater
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- wall
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H7/00—Storage heaters, i.e. heaters in which the energy is stored as heat in masses for subsequent release
- F24H7/02—Storage heaters, i.e. heaters in which the energy is stored as heat in masses for subsequent release the released heat being conveyed to a transfer fluid
- F24H7/04—Storage heaters, i.e. heaters in which the energy is stored as heat in masses for subsequent release the released heat being conveyed to a transfer fluid with forced circulation of the transfer fluid
- F24H7/0408—Storage heaters, i.e. heaters in which the energy is stored as heat in masses for subsequent release the released heat being conveyed to a transfer fluid with forced circulation of the transfer fluid using electrical energy supply
- F24H7/0433—Storage heaters, i.e. heaters in which the energy is stored as heat in masses for subsequent release the released heat being conveyed to a transfer fluid with forced circulation of the transfer fluid using electrical energy supply the transfer medium being water
Definitions
- This invention relates to an electric water heater. More particularly, this invention relates to a compact electric water heater for domestic use that is pressureless, continuously self-cleaning, insulated, and energy efficient.
- the water heater preferably comprises insulation having multiple air spaces.
- the water heater also preferably includes one or more of an automatic fill switch, an inlet temperature sensor with a thermostat connected thereto, a high limit switch and a top nesting container for mounting an electric heating element.
- the high limit switch is preferably connected to a sensor plate.
- the sensor plate detects the temperature of the heat transfer liquid in the tank. By detecting the temperature of the heat transfer liquid in the tank as opposed to detecting the temperature of the water in the coil, a more accurate reading of the temperature of the heat transfer liquid in the tank is obtained.
- Conventional domestic electric water heaters include a steel tank, insulated by foam encased in a metal jacket. Cold water runs into the steel tank. The cold water is heated by lower and upper heating elements. Hot water exits through a pipe. While hot water is drained from the pipe, cold water mixes with the remaining hot water thus reducing the temperature of the remaining water.
- Heating elements in conventional electric water heaters often fail before tank fail, and thus must be replaced more frequently than tanks. Replacement of the elements is a difficult task in conventional domestic electric water heaters and usually requires that the water supply be shut off and that the tank be drained prior to replacing the element.
- Conventional electric water heaters have several safety drawbacks. They are typically constructed of a single layer of metal. The single layer of metal can be a hazardous condition when a person comes in contact with the unit or the metal due to repairs or through casual contact. Conventional electric water heating units may also have electrical wires positioned near the metal surface, which if contacted by a frayed or loose live wire, could cause electric shock and significant injury to an individual.
- Another drawback of conventional water heater is that the many metal parts are prone to corrosion.
- the metal parts are also thermally conductive and are not ideal for insulating the heated water from ambient temperatures.
- One object of the electric water heater of the present invention is to provide an efficient and inexpensive means for controlling the heating element within a hot water tank such that the temperature of the water is consistently kept at a desired temperature.
- Another object of the present invention is to provide an electric water heater comprising: a tank having an inner wall and an outer wall wherein said inner wall and said outer wall are separated by a first open space region and said first open space region is filled at least partially with thermal insulation; further wherein said water tank is adapted to hold a quantity of non-pressurized and non-circulating heat transfer liquid; a top adapted to be separated from said tank, said top having an upper wall and lower wall wherein said upper wall and said lower wall are separated by a second open space region and said second open space region is filled at least partially with thermal insulation; at least one thermally conductive coil adapted to circulate water from a water inlet, said coil being mounted inside said tank and having said water inlet and a water outlet in communication with an exterior of said tank, further wherein said water inlet and said water outlet each extends outside of said water heater; at least one heating element attached to said top and positioned to extend downwardly through said top and heat said heat transfer liquid within said tank; a sensor plate in communication with said coil in a
- an electric water heater comprising: a tank having an inner wall and an outer wall wherein said inner wall and said outer wall are separated by at least a single first open space region and said first open space region is filled at least in part with thermal insulation; further wherein said water tank is adapted to hold a quantity of non-pressurized and non-circulating heat transfer liquid; a top adapted to be separated from said tank, said top having an upper wall and lower wall wherein said upper wall and said lower wall are separated by at least a single second open space region and said second open space region is filled at least in part with thermal insulation; said top further having an opening that can receive a heating element mount adapted to extend downwardly inside and fluidly communicate with said heat transfer fluid, wherein said mount is sealing engaged in said opening and held in place by a gasket and a lip having a larger diameter than said opening, at least one thermally conductive coil adapted to circulate water from a water inlet said coil being mounted inside said tank and having said water inlet and a water
- FIG. 1 shows a cross-sectional side view of a water heater with insulation according to the present invention.
- FIG. 2 shows a cross-sectional side view of a water heater with air space, cardboard and foam insulation according to the present invention.
- FIG. 3 shows a cross-sectional side view of a water heater with air space and cardboard insulation having a metallic foil reflector shield on the cardboard according to the present invention.
- FIG. 4 shows a cross-sectional side view of another embodiment of a water heater according to the present invention.
- FIG. 5 shows a cross-sectional view of a tank wall having a cardboard insert according to the present invention.
- FIG. 6 shows a perspective view of a top section of a water heater tank with recesses according to the present invention.
- FIG. 7 shows a cross-sectional cut-away view of a portion of a water heater top and sidewalls shown in FIG. 3 taken along lines 5 - 5 .
- FIG. 8 shows a top view of a water heater top with recesses according to the present invention.
- FIG. 9 shows a side view of a plurality of water heater coils together with a sensor pipe and thermostat combination according to an embodiment of the present invention.
- FIG. 10 shows a cross sectional side view of a top of a water heater according to preferred dimensions of the present invention.
- FIG. 11 shows a cross sectional side view of a water heater according to preferred dimensions of the present invention.
- FIGS. 1, 2, and 3 illustrate a water heater according to the present invention generally indicated as 1 .
- the water heater has a cylindrical tank 2 having inner walls 4 and outer walls 5 , preferably made of plastic, such as polypropylene, although many types of plastic may be used. Plastic is desirable because it is dent resistant, non-corrosive, and has low thermal conductivity.
- the tank preferably contains a sufficient quantity of heat transfer fluid to cover a plurality of coils 7 positioned inside the tank.
- the coils 7 may be finned outside and corrugated inside to maximize heat transfer.
- the coils are preferably continuously connected copper tubing.
- the inner walls 4 and outer walls 5 may be spaced any convenient distance apart depending on amount of insulation and air spaces, but are preferably about two to three inches apart.
- the insulation material may also be recyclable paper.
- a combination of different insulation materials may also be used.
- Foam insulation is commonly used in water heaters known in the art, but may split or crack, oftentimes due to thermal expansion and contraction, drying out, or simply age. These cracks may cause a decrease in the water heater's efficiency. Cellulose insulation is more stable and more preferred than foam insulation.
- the open space region 2 E will be layered with insulation material 6 in such a manner as to provide an air space 2 A between an outer wall and a first layer of corrugated card board, another air space 2 A between the first layer of corrugated cardboard and a layer of foam, and yet another air 2 A space between the layer of foam and a second layer of corrugated card board followed by an additional air space 2 A between the second layer of cardboard and an inner wall.
- a material to reflect radiant energy may be used in the insulation to increase its effectiveness.
- a preferred method is to use one or more layers of a metallic foil such as aluminum foil.
- open regions of space 2 E and 10 E are preferably incorporated to further improve the efficiency and energy saving capabilities of the water heater unit.
- the tank 2 may contain multiple open space regions 2 A separated by thermal insulation 6 , thereby further increasing the efficiency of the water heating unit 1 .
- the top 10 is preferably insulated with foam.
- the inner walls 4 and outer walls 5 of the tank, along with the upper wall 10 B and lower wall 10 C of the top 10 are typically constructed of a plastic material such as polypropylene, however other similar materials may be used for construction.
- Polypropylene has low thermal conductivity, is not electrically conductive, is dent resistant, lightweight, and inexpensive to manufacture. All are very desirable properties for a water heater.
- Spaces that exist between the inner walls 4 and outer walls 5 of the tank 2 and between the upper walls 10 B and lower walls 10 C of the top 10 may be insulated with thermal insulation 6 or preferably integrated cardboard and air spaces 2 A.
- the thickness of the thermal insulation 6 may vary to give the desired insulation.
- the plurality of open spaces lined with thermal insulation allows for a substantial reduction in the escape of heat through thermal conductive transfer. Increased heat retention by the water heater provides for greater energy efficiency.
- open spaces in the insulation substantially reduce or prevent atmospheric temperature from adversely affecting the internal temperature of the tank.
- the open space region 2 E between inner walls 4 and outer walls 5 and the open space region 10 E between the upper wall 10 B and lower wall 10 C is fractionally filled with a thermal insulation material 6 , e.g., foam thermal insulation, in order to form a lining on at least one wall's surface.
- a thermal insulation material 6 e.g., foam thermal insulation
- the insulation lining on a wall may have a thickness of about 1 ⁇ 4 of an inch (6.4 mm) to about 3 inches (7.6 cm), but should preferably have a thickness of about 1 inch (25.4 mm).
- the distance across the first open space region 2 E, measured along a line perpendicular to the foam lining on each wall should have a distance of at least about 1 ⁇ 8 of an inch (3.2 mm) between the linings of insulation or between a lining of insulation and a tank wall in order to sufficiently cause a breakage in thermal contact.
- the distance across the first open space region 2 E measures about 1 ⁇ 4 of an inch (6.4 mm) to about 1 ⁇ 2 of an inch (13 mm).
- the double-walled top 10 supports at least a single conventional electric heating element 11 .
- the heating element 11 is secured to a heating element mount 116 extending downward inside the tank 2 and beneath the surface of a heat transfer liquid 3 .
- a typical heat transfer liquid 3 is water, however DOWTHERM® or DOWFROST® available form Dow Chemical are suitable heat transfer liquids.
- the heating element mount 116 has a diameter larger than a center hole 117 .
- the element mount rests atop of center hole 117 and is held in place by a lip section 116 H found in the top thus forming a proper seal between the center hole 117 and a cover plate 116 F.
- a thermostat 14 can be mounted on a thermostat sensor plate 120 .
- the thermostat sensor plate extends from the water inlet coil up through a second hole 19 in the tank's top positioned adjacent to the center hole 117 .
- the thermostat 14 controls electric power to the heating element 11 for regulation of the temperature of the tank fluid 3 .
- the thermostat 14 can be held in place on the thermostat sensor plate 120 by a spring tension clip 50 (shown in FIG. 9) or by any other fastening means.
- a wire 220 passing through a channel 22 in the top 10 at a point above the high limit switch 15 and thermostat 14 are also provided. The wire 220 provides for electrical communication between an electrical wiring box, the thermostat 14 and the sensor plate 120 .
- a sensor plate 120 is preferably a thin copper plate and is preferably fixedly connected to a sensor 33 .
- the sensor 33 is preferably welded onto the cold-water inlet 8 .
- the sensor plate 120 is preferably about 24 inches inside the tank on the coil 7 .
- the change in temperature of the sensor plate 120 signals the thermostat 14 , which in turn signals the heating element 11 to heat the water in the tank 2 .
- the signal is produced until the water reaches a pre-set temperature. Once this pre-set temperature is reached, the thermostat 14 turns off the heating element 11 .
- the thermal conductivity of the incoming cold water provides a false reading of the temperature of the water in the tank.
- the thermostat reading begins to change. The colder the incoming water, the lower the thermostat temperature reading.
- the thermostat temperature reading in the tank will be higher than the pre-set thermostat temperature setting.
- the hot water in the coil 7 offsets the thermal conductivity of the cold water in the cold water line.
- the sensor plate 120 be positioned about 24 inches (61 cm) inside the tank on the coil 7 inside the tank 2 to prevent over heating. Accordingly by positioning the sensor plate 120 about 24 inches (61 cm) on the coil 7 , the thermal conductivity of a leaking pipe or a dripping faucet will not affect the thermostat sensor and cause continuous heating. Thus, the thermostat will operate as designed or predetermined.
- An opening 116 C constructed of a plastic material or its equivalent such as polypropylene is designed to insulate and contain an electrical wiring box 116 D.
- the electrical wiring box 116 D provides for an electrical connection between the power supply and the thermostat 14 , and the high limit switch 15 and the heating element 11 .
- a float 114 is attached to the cold water inlet 8 .
- the float 114 measures the water level in the tank and fills the tank through an automatic valve 112 when the water level in the tank falls below the necessary level.
- the automatic valve 112 is an in-line T-shaped connective joint.
- the automatic valve 112 due to displacement of water by the heating element mount 116 , the automatic valve 112 , which may be a float valve, should be turned-off when the heating element mount 116 is removed to prevent overfilling of the water tank and causing unnecessary overflow.
- FIG. 4 illustrates another embodiment of the present invention.
- a double-walled insulated top 10 supports at least a single conventional electric heating element 11 that is secured to a heating element mount 116 .
- the top 10 has an opening 116 A.
- the mount 116 is inserted through the opening 116 A in top 10 , and extends downward inside the tank 2 beneath the surface of the tank water 3 and may be held in place by, gasket 116 E and a lip and screws (not shown) that is larger in diameter than the opening 116 A.
- a thermostat 14 also of conventional design, can be mounted on one side of the heating element mount 116 , in thermal proximity to a sensor block 120 ′ in the coil line.
- the thermostat 14 controls electric power to the heating element 11 for regulation of the temperature of the tank water 3 .
- the thermostat 14 can be held in place by a flexible clip 116 B that has the capability to be bowed, thereby securing the position of the thermostat 14 inside the heating element mount 116 .
- An insert 116 C as shown in FIG. 4, preferably constructed of a plastic material, is designed to insulate and contain an electrical wiring box 116 D.
- the insert 116 C is placed into the opening 116 A of the heating element mount 116 .
- a third gasket 116 G resides where the insert 116 C contacts the electric heating mount 116 in order to ensure a proper seal between the elements, fastened by screws.
- the top 10 can simply rest atop of inner walls 4 and outer walls 5 of the tank 2 .
- the top 10 is fastened to the tank 2 using any conventional type of fastening device which allows for removal of the top 10 , including but not limited to clamps, latches, or screwing the top 10 onto the tank 2 using one or two pairs of mating threads or screws 26 on the top 10 and the inner wall 4 and/or outer wall 5 (See FIG. 4).
- Gaskets 16 are used to ensure a proper seal between the top 10 and the tank 2 to prevent any significant loss of heat.
- a water heater 1 has a top 10 that includes a center hole 117 .
- a heating element mount 116 descends through the center hole 117 into the tank water, preferably positioning the heating element 11 at approximately the center of the tank.
- a plastic lid 116 F (See FIG. 4) covering the insert 116 C, electrical wiring box 116 D, and gasket 116 E, is preferably insulated and used to cover the hole to limit heat loss through the center hole 117 .
- a thermostat 14 is preferably attached in close thermal contact with an inner wall of the mount 116 .
- the thermostat 14 can be held at the correct depth within the mount 116 using a depth extension holder 116 H in order to position the thermostat, and sensor block 120 ′, at least 2 inches (5 cm) below the water line within the tank 2 .
- the outer walls 5 of the container fit tightly against the sensor block 120 ′.
- the coil 7 is attached to the sensor block 120 ′. Because of the thermostat's position against the sensor block 120 ′, the heating element 11 will begin heating or raising the water temperature in the tank while water is being extracted from the coils 7 . Timing the heating to coincide with use raises the efficiency of the water heater.
- the sensor block 120 ′ is preferably a hollow block through which the incoming cold water flows before passing through the coiled section.
- the sensor block 120 ′ may also be an in-line sensor block.
- the sensor block 120 ′ is placed in close proximity with the thermostat 14 .
- the sensor block 120 ′ should preferably be aligned with the thermostat to improve the thermal contact between the devices. As hot water is drawn, cold water circulates through the sensor block 120 ′, thereby cooling the thermostat 14 .
- the sensor block 120 ′ could be configured in various ways to allow the flow of water.
- the connectors 122 and 124 for bringing water through the sensor block 120 ′ may be positioned on different faces of the sensor block 120 ′ or on the same face, vertically or horizontally.
- the sensor block 120 ′ preferably is made of any thermoconductive metal.
- an optional overflow pipe 17 may be located above the water level of the tank 2 or the second open space region which is located between the top surface of the tank water 3 and the top 10 .
- the overflow pipe extends horizontally through the second open space region and through the inner walls 4 of the tank and then vertically downward along the outer walls 5 of the tank 2 .
- the overflow pipe 17 if present, runs to an overflow pan 18 in which the water heater 1 sits.
- FIGS. 4 and 5 the insulation in the top 10 and tank 2 , each of which contain at least a single open space region 10 E, are designed to accommodate the elements of the preferred embodiment.
- the detailed cut-away of FIG. 4 depict a double-walled top 10 , having an upper wall 10 B and a lower wall 10 C, with an open space region 10 E existing between the walls.
- FIG. 5 depicts a double-walled tank 2 , having an inner wall 4 and outer wall 5 , with an opens space region 2 E existing between the walls.
- An amount of thermal insulation 6 such as fiberglass, foam, cellulose, corrugated cardboard or cardboard is introduced to one or more of the open space regions 2 E and 10 E in order to form a lining on at least one wall's surface.
- the insulation material may also be recyclable paper.
- Corrugated cardboard which provides additional air spaces between the corrugations, is a preferred insulation material. A combination of these may also be used.
- the open air space 2 E and 10 E will be layered to provide an air space 2 A and 10 A between an outer wall and a first layer of corrugated card board, another air space 2 A and 10 A between the first layer of corrugated cardboard and a layer of foam, and yet another air space 2 A and 10 A between the layer of foam and a second layer of corrugated card board followed by an additional air space 2 A and 10 A between the second layer of cardboard and an inner wall.
- the lining on a wall may have a thickness of about 1 ⁇ 4 of an inch (6.4 mm) to about 3 inches (7.6 cm), but should preferably have a thickness of about 1 inch (25.4 mm) such that the distance across the open space regions 2 E and 10 E, when measured along a line, perpendicular or any other suitable direction, to the lining on each wall, should have open air spaces 2 A and 10 A that provide a distance of at least about 1 ⁇ 8 of an inch (3.2 mm) between the linings of insulation or between a lining of insulation and a tank wall in order to sufficiently cause a breakage in thermal contact.
- the distance across the open space regions 2 E and 10 E preferably measures about 1 ⁇ 4 of an inch (6.4 mm) to about 1 ⁇ 2 of an inch (13 mm).
- This top 10 is configured so that it can receive and support at least a single conventional electric water heater element 11 or may accommodate at least a single conventional electric heating element 11 that is secured to a heating element mount 116 inserted through a center hole 117 in the top 10 .
- FIG. 6 shows a section of the water heater tank 2 including the top 10 and the tank outer wall 5 according to another embodiment of the present invention.
- the top 10 and the outer wall 5 are preferably made of polypropylene or any similar synthetic material.
- the top 10 comprises a cover plate cavity 21 for receiving the heating element 11 , sensor pipe 120 and thermostat 14 .
- the cover plate cavity 21 may be located anywhere on the top surface such that the cover plate cavity 21 is easily accessible for inserting elements such as the heating element 11 , sensor pipe 120 , thermostat 14 , and high limit switch 15 .
- the cover plate cavity 21 houses a heating element insert cavity 20 for receiving an electric heating element 11 , an electrical wire channel 22 to connect the wiring, a thermostat cavity 23 , and an electrical box cavity 24 .
- the cavities 20 , 23 , 24 and electrical wire channel 22 may be arranged in any suitable manner.
- the top also houses a fill plug cavity 25 , which may be positioned in any suitable position on said top 10 .
- the fill plug cavity allows for an additional means for filling the water heater upon installation.
- the cold water inlet 8 and hot water outlet 9 are also shown in FIG. 6. Cold water to be heated inside the tank 2 enters the coil 7 at a cold-water inlet 8 , circulates through the finned tube coils, and exits through the hot water outlet 9 .
- the top 2 may be secured to the tank via attaching screws 26 .
- the electrical box cavity 24 is preferably a length L W of about 1 ⁇ 4 inch (6.4 mm) and a width W W of about 1 inch (25.4 mm).
- a fill plug 27 for inserting in the fill plug cavity 25 is preferably a length L F of about 3 inches (7.6 cm) and a width W F of about 2 inches (5.1 cm) and is about 1 & 1 ⁇ 2 inches deep (38 mm).
- the fill plug cavity 25 preferably has a diameter d F of about 2 inches (5.1 cm).
- the outside diameter OD of the top is preferably about 23 inches (58.4 cm).
- the heating element cavity 20 is adjacent the thermostat cavity 23 and the thermostat cavity 23 is adjacent the electrical box cavity 24 , in such a manner that the thermostat cavity 23 and high limit switch cavity are between the heating element cavity 20 and the electrical box cavity 24 .
- the electrical wire channel 22 preferably lies beneath the cover plate and is in communication with the cavities 20 , 23 , and 24 .
- the first recess 30 supports the heating element cavity 20 and is preferably about 1 ⁇ 4 of an inch (6.4 mm).
- the second recess 31 supports the thermostat cavity 23 and the electrical box cavity 24 and is preferably about 1 ⁇ 8 of an inch 3.2 mm).
- the heating element cavity 20 is preferably a length L H of about 4 & 1 ⁇ 8 inches (10.5 cm) and a width W H of about 4 & 1 ⁇ 8 inches (10.5 cm).
- the thermostat cavity 23 is preferably a length LE of about 3 inches (7.6 cm), a width WE of about 3 inches (7.6 cm), and a depth of about 3 inches (7.6 cm).
- the electrical box cavity 24 is preferably a length L T of about 2 inches (5.1 cm), a width WT of about 3 inches (7.6 cm), and a depth of about 1 & 1 ⁇ 2 inches (38 mm).
- the thermostat cavity 23 also has a hole 32 for a pipe sensor.
- FIG. 7 a channel 40 is molded inside a lower section of the top 10 to house the cold-water inlet 8 and hot water outlet 9 .
- FIG. 10 shows an arch 64 in the bottom of the top 10 , which allows the pipes 8 & 9 to exit.
- the thermostat and high limit switch are a single unitary body 51 and is connected to a sensor (not shown) via springs 50 .
- the top 10 ′ is preferably a thickness t 1 of about 3 & 1 ⁇ 4 inches (8.3 cm) and a diameter D 1 of about 23 inches (58.4 cm).
- the top 10 ′ is machined to have three levels wherein the first level 61 overhang the second level 62 and the second level 62 overhangs the third level 63 .
- the first level 61 preferably proceeds downward from the upper wall 10 B a distance L 1 of about 1 & 1 ⁇ 4 inches (31.8 mm) and offsets the second level 62 by a width W 1 of about 1 ⁇ 8 of an inch (3.2 mm).
- the second level 62 preferably proceeds downward from the first level 61 a distance L 2 of about 1 & 1 ⁇ 4 inches (31.8 mm) and offsets the third level 63 by a width W 2 of about 2 & 3 ⁇ 8 inches (6 cm).
- the third level 63 preferably proceeds downward from the second level 62 a distance L 3 of about 3 ⁇ 4 of an inch (19 mm).
- the cut-away section 64 is preferably in an arch shape and is suitable to accommodate at least two pipes 66 each having a 3 ⁇ 4 0 of an inch (19 mm) outside diameter.
- the top 10 ′′ has the same dimensions as top 10 ′, however the top 10 ′′ does not include cutout section 64 .
- the top 10 ′′ supports at least a single conventional electric heating element 11 that is secured to a heating mount has a cut-away section 67 having a diameter D 2 of about 14 inches (35.6 cm) and thickness t 2 of about 1 ⁇ 8 of an inch (3.2 mm) for securely holding a cover plate 116 F.
- the top 10 ′′ comprises a center hole 117 extending through the top 10 ′′ having a length L 4 that is sufficient to contain a heating element.
- the second hole 19 is preferably a length L 6 of about 3 inches (7.6 cm) and a width W 4 of about 3 inches (7.6 cm).
- the top 10 ′′ also contains an opening 116 C, which is preferably a deep recess having a length L 7 of about 3 inches (7.6 cm), width W 7 of about 2 inches (5.1 cm) and a height (not shown) of about 1-1 ⁇ 2 inches (38.1 mm).
- the tank 2 preferably has an inside diameter D 3 of about 18 inches (45.7 cm) and an outside diameter D 4 of about 23 inches (58.4 cm).
- the outer walls 5 of the tank 2 preferably extend a length L 8 of about 1 & 1 ⁇ 4 inches (31.8 mm) above the inner wall 4 and insulation 6 therebetween.
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Abstract
Description
- 1. Technical Field
- This invention relates to an electric water heater. More particularly, this invention relates to a compact electric water heater for domestic use that is pressureless, continuously self-cleaning, insulated, and energy efficient. The water heater preferably comprises insulation having multiple air spaces. The water heater also preferably includes one or more of an automatic fill switch, an inlet temperature sensor with a thermostat connected thereto, a high limit switch and a top nesting container for mounting an electric heating element. The high limit switch is preferably connected to a sensor plate. The sensor plate detects the temperature of the heat transfer liquid in the tank. By detecting the temperature of the heat transfer liquid in the tank as opposed to detecting the temperature of the water in the coil, a more accurate reading of the temperature of the heat transfer liquid in the tank is obtained.
- 2. Background Art
- Conventional domestic electric water heaters include a steel tank, insulated by foam encased in a metal jacket. Cold water runs into the steel tank. The cold water is heated by lower and upper heating elements. Hot water exits through a pipe. While hot water is drained from the pipe, cold water mixes with the remaining hot water thus reducing the temperature of the remaining water.
- In a conventional electric water heater, minerals typically settle out from the water to form sediments. Accumulation of sediments can eventually cause corrosion and leaks thereby reducing the heater's efficiency. These inefficiencies lead to increased costs of heating. Furthermore, heat and occasionally excessive pressure of water entering the system from the cold-water source is generated in the tightly sealed tank. Property damage and personal injury can result from steam and water leaving the pressure relief valve or from explosion due to a failed valve.
- Heating elements in conventional electric water heaters often fail before tank fail, and thus must be replaced more frequently than tanks. Replacement of the elements is a difficult task in conventional domestic electric water heaters and usually requires that the water supply be shut off and that the tank be drained prior to replacing the element.
- Conventional electric water heaters have several safety drawbacks. They are typically constructed of a single layer of metal. The single layer of metal can be a hazardous condition when a person comes in contact with the unit or the metal due to repairs or through casual contact. Conventional electric water heating units may also have electrical wires positioned near the metal surface, which if contacted by a frayed or loose live wire, could cause electric shock and significant injury to an individual.
- Another drawback of conventional water heater is that the many metal parts are prone to corrosion. The metal parts are also thermally conductive and are not ideal for insulating the heated water from ambient temperatures.
- One object of the electric water heater of the present invention is to provide an efficient and inexpensive means for controlling the heating element within a hot water tank such that the temperature of the water is consistently kept at a desired temperature.
- Another object of the present invention is to provide an electric water heater comprising: a tank having an inner wall and an outer wall wherein said inner wall and said outer wall are separated by a first open space region and said first open space region is filled at least partially with thermal insulation; further wherein said water tank is adapted to hold a quantity of non-pressurized and non-circulating heat transfer liquid; a top adapted to be separated from said tank, said top having an upper wall and lower wall wherein said upper wall and said lower wall are separated by a second open space region and said second open space region is filled at least partially with thermal insulation; at least one thermally conductive coil adapted to circulate water from a water inlet, said coil being mounted inside said tank and having said water inlet and a water outlet in communication with an exterior of said tank, further wherein said water inlet and said water outlet each extends outside of said water heater; at least one heating element attached to said top and positioned to extend downwardly through said top and heat said heat transfer liquid within said tank; a sensor plate in communication with said coil in a position proximate to said water inlet and wherein said sensor plate extends from said top to said coil; a thermostat connected to said sensor plate, wherein said thermostat is in thermal proximity with said sensor plate such that it activates said heating element when the temperature signaled by said sensor plate reaches a predetermined temperature; and wherein said heating element contacts and heats the heat transfer liquid inside the tank and said heat transfer liquid contacts said coil to heat water from a water supply that enters said water heater and circulates through said coil such that heated water leaves said water outlet.
- It is another object of the present invention to provide an electric water heater comprising: a tank having an inner wall and an outer wall wherein said inner wall and said outer wall are separated by at least a single first open space region and said first open space region is filled at least in part with thermal insulation; further wherein said water tank is adapted to hold a quantity of non-pressurized and non-circulating heat transfer liquid; a top adapted to be separated from said tank, said top having an upper wall and lower wall wherein said upper wall and said lower wall are separated by at least a single second open space region and said second open space region is filled at least in part with thermal insulation; said top further having an opening that can receive a heating element mount adapted to extend downwardly inside and fluidly communicate with said heat transfer fluid, wherein said mount is sealing engaged in said opening and held in place by a gasket and a lip having a larger diameter than said opening, at least one thermally conductive coil adapted to circulate water from a water inlet said coil being mounted inside said tank and having said water inlet and a water outlet in communication with an exterior of said tank, further wherein said water inlet and said water outlet each extends outside of said water heater; at least one heating element mounted on said heating element mount and positioned to extend inside said heat transfer liquid within said tank; a sensor block in communication with said coil for receiving water from said coil and returning water to said coil; and a thermostat mounted on a side of said heating element mount and in thermal proximity to said sensor block such that it activates said heating element when water temperature signaled by said sensor block reaches a pre-determined temperature.
- FIG. 1 shows a cross-sectional side view of a water heater with insulation according to the present invention.
- FIG. 2 shows a cross-sectional side view of a water heater with air space, cardboard and foam insulation according to the present invention.
- FIG. 3 shows a cross-sectional side view of a water heater with air space and cardboard insulation having a metallic foil reflector shield on the cardboard according to the present invention.
- FIG. 4 shows a cross-sectional side view of another embodiment of a water heater according to the present invention.
- FIG. 5 shows a cross-sectional view of a tank wall having a cardboard insert according to the present invention.
- FIG. 6 shows a perspective view of a top section of a water heater tank with recesses according to the present invention.
- FIG. 7 shows a cross-sectional cut-away view of a portion of a water heater top and sidewalls shown in FIG. 3 taken along lines5-5.
- FIG. 8 shows a top view of a water heater top with recesses according to the present invention.
- FIG. 9 shows a side view of a plurality of water heater coils together with a sensor pipe and thermostat combination according to an embodiment of the present invention.
- FIG. 10 shows a cross sectional side view of a top of a water heater according to preferred dimensions of the present invention.
- FIG. 11 shows a cross sectional side view of a water heater according to preferred dimensions of the present invention.
- Applicant's invention will be best understood when considered in light of the following description of the embodiments of the invention as illustrated in the attached drawings wherein like reference numerals refer to like parts. The embodiments of the figures are preferred embodiments, but do not restrict the scope of the invention.
- FIGS. 1, 2, and3 illustrate a water heater according to the present invention generally indicated as 1. The water heater has a
cylindrical tank 2 havinginner walls 4 andouter walls 5, preferably made of plastic, such as polypropylene, although many types of plastic may be used. Plastic is desirable because it is dent resistant, non-corrosive, and has low thermal conductivity. In use, the tank preferably contains a sufficient quantity of heat transfer fluid to cover a plurality of coils 7 positioned inside the tank. The coils 7 may be finned outside and corrugated inside to maximize heat transfer. The coils are preferably continuously connected copper tubing. Theinner walls 4 andouter walls 5 may be spaced any convenient distance apart depending on amount of insulation and air spaces, but are preferably about two to three inches apart. A first open space region 2E, shown in more detail in FIGS. 4 and 5, between theinner wall 4 andouter wall 5 is filled with a thermal insulation material 6 preferably made from cellulose, cardboard, corrugated cardboard, foam or cellulose fibers. The insulation material may also be recyclable paper. Corrugated cardboard, which provides additional air spaces between corrugations, is also a preferred insulation material. A combination of different insulation materials may also be used. Foam insulation is commonly used in water heaters known in the art, but may split or crack, oftentimes due to thermal expansion and contraction, drying out, or simply age. These cracks may cause a decrease in the water heater's efficiency. Cellulose insulation is more stable and more preferred than foam insulation. Preferably, the open space region 2E, will be layered with insulation material 6 in such a manner as to provide an air space 2A between an outer wall and a first layer of corrugated card board, another air space 2A between the first layer of corrugated cardboard and a layer of foam, and yet another air 2A space between the layer of foam and a second layer of corrugated card board followed by an additional air space 2A between the second layer of cardboard and an inner wall. - Additionally, a material to reflect radiant energy may be used in the insulation to increase its effectiveness. A preferred method is to use one or more layers of a metallic foil such as aluminum foil.
- As shown in detail in FIG. 4, open regions of space2E and 10E are preferably incorporated to further improve the efficiency and energy saving capabilities of the water heater unit. Additionally, the
tank 2 may contain multiple open space regions 2A separated by thermal insulation 6, thereby further increasing the efficiency of thewater heating unit 1. The top 10 is preferably insulated with foam. - In addition, the
inner walls 4 andouter walls 5 of the tank, along with the upper wall 10B andlower wall 10C of the top 10 are typically constructed of a plastic material such as polypropylene, however other similar materials may be used for construction. Polypropylene has low thermal conductivity, is not electrically conductive, is dent resistant, lightweight, and inexpensive to manufacture. All are very desirable properties for a water heater. - Spaces that exist between the
inner walls 4 andouter walls 5 of thetank 2 and between the upper walls 10B andlower walls 10C of the top 10 may be insulated with thermal insulation 6 or preferably integrated cardboard and air spaces 2A. The thickness of the thermal insulation 6 may vary to give the desired insulation. Preferably there is a volume of open space in the insulation lining between the inner and outer walls. The plurality of open spaces lined with thermal insulation, allows for a substantial reduction in the escape of heat through thermal conductive transfer. Increased heat retention by the water heater provides for greater energy efficiency. Furthermore, open spaces in the insulation substantially reduce or prevent atmospheric temperature from adversely affecting the internal temperature of the tank. - Greater thickness of the lining of insulation results in greater efficiency of the water heater. For example, tank walls spaced 4 inches apart result in a water heater of greater efficiency than a water heater with tank walls spaced 2 inches apart because of the greater width of the breakage in thermal contact. Preferably, the open space region2E between
inner walls 4 andouter walls 5 and the open space region 10E between the upper wall 10B andlower wall 10C is fractionally filled with a thermal insulation material 6, e.g., foam thermal insulation, in order to form a lining on at least one wall's surface. - The insulation lining on a wall may have a thickness of about ¼ of an inch (6.4 mm) to about 3 inches (7.6 cm), but should preferably have a thickness of about 1 inch (25.4 mm). The distance across the first open space region2E, measured along a line perpendicular to the foam lining on each wall should have a distance of at least about ⅛ of an inch (3.2 mm) between the linings of insulation or between a lining of insulation and a tank wall in order to sufficiently cause a breakage in thermal contact. Preferably, the distance across the first open space region 2E measures about ¼ of an inch (6.4 mm) to about ½ of an inch (13 mm).
- Conventional electric water heaters often do not incorporate a design using double walled construction of the
plastic tank 2. The improved design of one embodiment of the present invention has the outside of the tank larger and taller than the inside of the tank, which prevents leakage from theinner tank wall 4. By controlling leakage, the water heater is prevented from causing water damage to the surrounding areas. In addition, using plastic instead of metallic materials for the tank prevents conduction of electrical current and thus provides a safer electric water heater than conventional models. - As shown in FIG. 1, the double-walled top10 supports at least a single conventional
electric heating element 11. Theheating element 11 is secured to aheating element mount 116 extending downward inside thetank 2 and beneath the surface of aheat transfer liquid 3. A typicalheat transfer liquid 3 is water, however DOWTHERM® or DOWFROST® available form Dow Chemical are suitable heat transfer liquids. Theheating element mount 116 has a diameter larger than acenter hole 117. The element mount rests atop ofcenter hole 117 and is held in place by alip section 116H found in the top thus forming a proper seal between thecenter hole 117 and acover plate 116F. - A
thermostat 14, also of conventional design, can be mounted on athermostat sensor plate 120. The thermostat sensor plate extends from the water inlet coil up through asecond hole 19 in the tank's top positioned adjacent to thecenter hole 117. Thethermostat 14 controls electric power to theheating element 11 for regulation of the temperature of thetank fluid 3. Thethermostat 14 can be held in place on thethermostat sensor plate 120 by a spring tension clip 50 (shown in FIG. 9) or by any other fastening means. Awire 220 passing through a channel 22 in the top 10 at a point above thehigh limit switch 15 andthermostat 14 are also provided. Thewire 220 provides for electrical communication between an electrical wiring box, thethermostat 14 and thesensor plate 120. - A
sensor plate 120 is preferably a thin copper plate and is preferably fixedly connected to asensor 33. Thesensor 33 is preferably welded onto the cold-water inlet 8. Thesensor plate 120 is preferably about 24 inches inside the tank on the coil 7. As hot water is drawn, cold water circulating through the coils cools thesensor plate 120. The change in temperature of thesensor plate 120 signals thethermostat 14, which in turn signals theheating element 11 to heat the water in thetank 2. The signal is produced until the water reaches a pre-set temperature. Once this pre-set temperature is reached, thethermostat 14 turns off theheating element 11. - Generally having the
sensor plate 120 at the beginning of the coil inside the tank when a hot water faucet runs or drips, causes the thermostat to continuously run due to cold water entering the coil and thermally cooling thesensor plate 120. Subsequently, the water heater will heat to a higher temperature than that for which the thermostat is preset, causing thehigh limit switch 15 to shut down the water heater. Thehigh limit switch 15 is fixedly connected to a high limitswitch sensor plate 34, which extends downward into the water and senses the water temperature in the tank. Thesensor plate 34 does not sense the water in the coil 7. This provides for a more accurate reading of the water temperature in the tank. - Also, when a sensor is positioned close to the cold-
water inlet 8, the thermal conductivity of the incoming cold water provides a false reading of the temperature of the water in the tank. When the incoming water temperature drops below 60° F. (16° C.), the thermostat reading begins to change. The colder the incoming water, the lower the thermostat temperature reading. Thus, the thermostat temperature reading in the tank will be higher than the pre-set thermostat temperature setting. Generally, if the sensor is too close to the incoming cold water line, the cold water will cause a lower reading. When the sensor is positioned further inside the tank, the hot water in the coil 7 offsets the thermal conductivity of the cold water in the cold water line. - It is preferred that the
sensor plate 120 be positioned about 24 inches (61 cm) inside the tank on the coil 7 inside thetank 2 to prevent over heating. Accordingly by positioning thesensor plate 120 about 24 inches (61 cm) on the coil 7, the thermal conductivity of a leaking pipe or a dripping faucet will not affect the thermostat sensor and cause continuous heating. Thus, the thermostat will operate as designed or predetermined. - An
opening 116C, constructed of a plastic material or its equivalent such as polypropylene is designed to insulate and contain anelectrical wiring box 116D. Theelectrical wiring box 116D provides for an electrical connection between the power supply and thethermostat 14, and thehigh limit switch 15 and theheating element 11. - As shown in FIGS.1-4, a
float 114 is attached to thecold water inlet 8. Thefloat 114 measures the water level in the tank and fills the tank through anautomatic valve 112 when the water level in the tank falls below the necessary level. In a preferred embodiment, theautomatic valve 112 is an in-line T-shaped connective joint. However, due to displacement of water by theheating element mount 116, theautomatic valve 112, which may be a float valve, should be turned-off when theheating element mount 116 is removed to prevent overfilling of the water tank and causing unnecessary overflow. - FIG. 4 illustrates another embodiment of the present invention. A double-walled insulated top10 supports at least a single conventional
electric heating element 11 that is secured to aheating element mount 116. The top 10 has anopening 116A. Themount 116 is inserted through theopening 116A in top 10, and extends downward inside thetank 2 beneath the surface of thetank water 3 and may be held in place by, gasket 116E and a lip and screws (not shown) that is larger in diameter than theopening 116A. Thus forming a proper seal between theopening 116A and themount 116. Athermostat 14, also of conventional design, can be mounted on one side of theheating element mount 116, in thermal proximity to asensor block 120′ in the coil line. Thethermostat 14 controls electric power to theheating element 11 for regulation of the temperature of thetank water 3. Thethermostat 14 can be held in place by a flexible clip 116B that has the capability to be bowed, thereby securing the position of thethermostat 14 inside theheating element mount 116. - An
insert 116C, as shown in FIG. 4, preferably constructed of a plastic material, is designed to insulate and contain anelectrical wiring box 116D. Theinsert 116C is placed into theopening 116A of theheating element mount 116. In addition, a third gasket 116G resides where theinsert 116C contacts theelectric heating mount 116 in order to ensure a proper seal between the elements, fastened by screws. - As shown in FIG. 4, the top10 can simply rest atop of
inner walls 4 andouter walls 5 of thetank 2. Preferably, the top 10 is fastened to thetank 2 using any conventional type of fastening device which allows for removal of the top 10, including but not limited to clamps, latches, or screwing the top 10 onto thetank 2 using one or two pairs of mating threads or screws 26 on the top 10 and theinner wall 4 and/or outer wall 5 (See FIG. 4).Gaskets 16 are used to ensure a proper seal between the top 10 and thetank 2 to prevent any significant loss of heat. - As shown in FIG. 4, a
water heater 1 has a top 10 that includes acenter hole 117. Aheating element mount 116 descends through thecenter hole 117 into the tank water, preferably positioning theheating element 11 at approximately the center of the tank. Aplastic lid 116F (See FIG. 4) covering theinsert 116C,electrical wiring box 116D, and gasket 116E, is preferably insulated and used to cover the hole to limit heat loss through thecenter hole 117. Athermostat 14 is preferably attached in close thermal contact with an inner wall of themount 116. Thethermostat 14 can be held at the correct depth within themount 116 using adepth extension holder 116H in order to position the thermostat, and sensor block 120′, at least 2 inches (5 cm) below the water line within thetank 2. Theouter walls 5 of the container fit tightly against thesensor block 120′. The coil 7 is attached to thesensor block 120′. Because of the thermostat's position against thesensor block 120′, theheating element 11 will begin heating or raising the water temperature in the tank while water is being extracted from the coils 7. Timing the heating to coincide with use raises the efficiency of the water heater. - The
sensor block 120′ is preferably a hollow block through which the incoming cold water flows before passing through the coiled section. Thesensor block 120′ may also be an in-line sensor block. Thesensor block 120′ is placed in close proximity with thethermostat 14. Thesensor block 120′ should preferably be aligned with the thermostat to improve the thermal contact between the devices. As hot water is drawn, cold water circulates through thesensor block 120′, thereby cooling thethermostat 14. Thesensor block 120′ could be configured in various ways to allow the flow of water. In particular, theconnectors sensor block 120′ may be positioned on different faces of thesensor block 120′ or on the same face, vertically or horizontally. Thesensor block 120′ preferably is made of any thermoconductive metal. - As shown in FIG. 4, an
optional overflow pipe 17 may be located above the water level of thetank 2 or the second open space region which is located between the top surface of thetank water 3 and the top 10. The overflow pipe extends horizontally through the second open space region and through theinner walls 4 of the tank and then vertically downward along theouter walls 5 of thetank 2. Theoverflow pipe 17, if present, runs to anoverflow pan 18 in which thewater heater 1 sits. - It should be noted that the only pressurized water is in the coil. This provides a safety advantage over electric water heaters known in the art. If the water pressure is increased until the water heater failed, the burst would be contained by the heat transfer fluid, the
inner wall 4, theouter wall 5, and the top 10 of the heater. Therefore, there is also no need for a pressure relief valve as is required by water heaters know in the art. - In another embodiment of the present invention, shown in FIGS. 4 and 5, the insulation in the top10 and
tank 2, each of which contain at least a single open space region 10E, are designed to accommodate the elements of the preferred embodiment. The detailed cut-away of FIG. 4 depict a double-walled top 10, having an upper wall 10B and alower wall 10C, with an open space region 10E existing between the walls. FIG. 5 depicts a double-walled tank 2, having aninner wall 4 andouter wall 5, with an opens space region 2E existing between the walls. An amount of thermal insulation 6, such as fiberglass, foam, cellulose, corrugated cardboard or cardboard is introduced to one or more of the open space regions 2E and 10E in order to form a lining on at least one wall's surface. - The insulation material may also be recyclable paper. Corrugated cardboard, which provides additional air spaces between the corrugations, is a preferred insulation material. A combination of these may also be used. Preferably, the open air space2E and 10E, will be layered to provide an air space 2A and 10A between an outer wall and a first layer of corrugated card board, another air space 2A and 10A between the first layer of corrugated cardboard and a layer of foam, and yet another air space 2A and 10A between the layer of foam and a second layer of corrugated card board followed by an additional air space 2A and 10A between the second layer of cardboard and an inner wall.
- The lining on a wall may have a thickness of about ¼ of an inch (6.4 mm) to about 3 inches (7.6 cm), but should preferably have a thickness of about 1 inch (25.4 mm) such that the distance across the open space regions2E and 10E, when measured along a line, perpendicular or any other suitable direction, to the lining on each wall, should have open air spaces 2A and 10A that provide a distance of at least about ⅛ of an inch (3.2 mm) between the linings of insulation or between a lining of insulation and a tank wall in order to sufficiently cause a breakage in thermal contact. However, the distance across the open space regions 2E and 10E preferably measures about ¼ of an inch (6.4 mm) to about ½ of an inch (13 mm).
- This top10 is configured so that it can receive and support at least a single conventional electric
water heater element 11 or may accommodate at least a single conventionalelectric heating element 11 that is secured to aheating element mount 116 inserted through acenter hole 117 in the top 10. - FIG. 6 shows a section of the
water heater tank 2 including the top 10 and the tankouter wall 5 according to another embodiment of the present invention. The top 10 and theouter wall 5 are preferably made of polypropylene or any similar synthetic material. The top 10 comprises acover plate cavity 21 for receiving theheating element 11,sensor pipe 120 andthermostat 14. Thecover plate cavity 21 may be located anywhere on the top surface such that thecover plate cavity 21 is easily accessible for inserting elements such as theheating element 11,sensor pipe 120,thermostat 14, andhigh limit switch 15. Thecover plate cavity 21 houses a heatingelement insert cavity 20 for receiving anelectric heating element 11, an electrical wire channel 22 to connect the wiring, athermostat cavity 23, and anelectrical box cavity 24. Thecavities fill plug cavity 25, which may be positioned in any suitable position on saidtop 10. The fill plug cavity allows for an additional means for filling the water heater upon installation. Thecold water inlet 8 andhot water outlet 9 are also shown in FIG. 6. Cold water to be heated inside thetank 2 enters the coil 7 at a cold-water inlet 8, circulates through the finned tube coils, and exits through thehot water outlet 9. The top 2 may be secured to the tank via attaching screws 26. - As shown in FIG. 8, the
electrical box cavity 24 is preferably a length LW of about ¼ inch (6.4 mm) and a width WW of about 1 inch (25.4 mm). Afill plug 27 for inserting in thefill plug cavity 25 is preferably a length LF of about 3 inches (7.6 cm) and a width WF of about 2 inches (5.1 cm) and is about 1 & ½ inches deep (38 mm). Thefill plug cavity 25 preferably has a diameter dF of about 2 inches (5.1 cm). The outside diameter OD of the top is preferably about 23 inches (58.4 cm). In a preferred embodiment of the present invention, theheating element cavity 20 is adjacent thethermostat cavity 23 and thethermostat cavity 23 is adjacent theelectrical box cavity 24, in such a manner that thethermostat cavity 23 and high limit switch cavity are between theheating element cavity 20 and theelectrical box cavity 24. The electrical wire channel 22 preferably lies beneath the cover plate and is in communication with thecavities first recess 30 and asecond recess 31 in saidcover plate cavity 21. Thefirst recess 30 supports theheating element cavity 20 and is preferably about ¼ of an inch (6.4 mm). Thesecond recess 31 supports thethermostat cavity 23 and theelectrical box cavity 24 and is preferably about ⅛ of an inch 3.2 mm). Theheating element cavity 20 is preferably a length LH of about 4 & ⅛ inches (10.5 cm) and a width WH of about 4 & ⅛ inches (10.5 cm). Thethermostat cavity 23 is preferably a length LE of about 3 inches (7.6 cm), a width WE of about 3 inches (7.6 cm), and a depth of about 3 inches (7.6 cm). Theelectrical box cavity 24 is preferably a length LT of about 2 inches (5.1 cm), a width WT of about 3 inches (7.6 cm), and a depth of about 1 & ½ inches (38 mm). Thethermostat cavity 23 also has a hole 32 for a pipe sensor. - As shown in FIG. 7, a channel40 is molded inside a lower section of the top 10 to house the cold-
water inlet 8 andhot water outlet 9. FIG. 10 shows an arch 64 in the bottom of the top 10, which allows thepipes 8 & 9 to exit. - In another embodiment of the present invention shown in FIG. 9, the thermostat and high limit switch are a single unitary body51 and is connected to a sensor (not shown) via springs 50.
- Referring to another embodiment of the present invention shown in FIG. 10, the top10′ is preferably a thickness t1 of about 3 & ¼ inches (8.3 cm) and a diameter D1 of about 23 inches (58.4 cm). The top 10′ is machined to have three levels wherein the first level 61 overhang the
second level 62 and thesecond level 62 overhangs thethird level 63. The first level 61 preferably proceeds downward from the upper wall 10B a distance L1 of about 1 & ¼ inches (31.8 mm) and offsets thesecond level 62 by a width W1 of about ⅛ of an inch (3.2 mm). Thesecond level 62 preferably proceeds downward from the first level 61 a distance L2 of about 1 & ¼ inches (31.8 mm) and offsets thethird level 63 by a width W2 of about 2 & ⅜ inches (6 cm). Thethird level 63 preferably proceeds downward from the second level 62 a distance L3 of about ¾ of an inch (19 mm). There is preferably a cut-awaysection 64 in thelower wall 10C. The cut-awaysection 64 is preferably in an arch shape and is suitable to accommodate at least two pipes 66 each having a ¾0 of an inch (19 mm) outside diameter. - Referring to yet another embodiment of the present invention shown in FIG. 11, the top10″ has the same dimensions as top 10′, however the top 10″ does not include
cutout section 64. The top 10″ supports at least a single conventionalelectric heating element 11 that is secured to a heating mount has a cut-away section 67 having a diameter D2 of about 14 inches (35.6 cm) and thickness t2 of about ⅛ of an inch (3.2 mm) for securely holding acover plate 116F. The top 10″ comprises acenter hole 117 extending through the top 10″ having a length L4 that is sufficient to contain a heating element. There is preferably a recess formed at the top of thecenter hole 117 between thecenter hole 117 and anouter edge 70 of cut-away section 67 having a length L5 of about ¾ of an inch (19 mm). - There is further provided a
second hole 19 adjacent to thecenter hole 117 in the tank's top for containing a thermostat and sensor. Thesecond hole 19 is preferably a length L6 of about 3 inches (7.6 cm) and a width W4 of about 3 inches (7.6 cm). The top 10″ also contains anopening 116C, which is preferably a deep recess having a length L7 of about 3 inches (7.6 cm), width W7 of about 2 inches (5.1 cm) and a height (not shown) of about 1-½ inches (38.1 mm). - The
tank 2 preferably has an inside diameter D3 of about 18 inches (45.7 cm) and an outside diameter D4 of about 23 inches (58.4 cm). Theouter walls 5 of thetank 2 preferably extend a length L8 of about 1 & ¼ inches (31.8 mm) above theinner wall 4 and insulation 6 therebetween. - Thus, although there have been described particular embodiments of the present invention of a new and useful water heater, it is not intended that such references are construed as limitations upon the scope of this invention.
Claims (27)
Priority Applications (3)
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US09/897,036 US6577817B2 (en) | 2001-07-03 | 2001-07-03 | Water heater |
CNA028172566A CN1551967A (en) | 2001-07-03 | 2002-06-19 | Water heater |
PCT/US2002/019252 WO2003004940A1 (en) | 2001-07-03 | 2002-06-19 | Water heater |
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US09/897,036 US6577817B2 (en) | 2001-07-03 | 2001-07-03 | Water heater |
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US6577817B2 US6577817B2 (en) | 2003-06-10 |
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US09/897,036 Expired - Fee Related US6577817B2 (en) | 2001-07-03 | 2001-07-03 | Water heater |
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US (1) | US6577817B2 (en) |
CN (1) | CN1551967A (en) |
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Also Published As
Publication number | Publication date |
---|---|
WO2003004940A1 (en) | 2003-01-16 |
CN1551967A (en) | 2004-12-01 |
US6577817B2 (en) | 2003-06-10 |
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